US5560168A - Swinging door with mirror insert on one face and method of making same - Google Patents

Swinging door with mirror insert on one face and method of making same Download PDF

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Publication number
US5560168A
US5560168A US08/402,003 US40200395A US5560168A US 5560168 A US5560168 A US 5560168A US 40200395 A US40200395 A US 40200395A US 5560168 A US5560168 A US 5560168A
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United States
Prior art keywords
molding
skin
mirror
aperture
hollow core
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Expired - Fee Related
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US08/402,003
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Robert J. Gagne
II William J. Plein
Kenneth R. Carson
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RENIN CORP US
Ableco Finance LLC
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Stanley Works
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Assigned to STANLEY WORKS, THE reassignment STANLEY WORKS, THE ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CARSON, KENNETH R., GAGNE, ROBERT J., PLEIN, WILLIAM J., II
Priority to CA002169586A priority patent/CA2169586C/en
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Publication of US5560168A publication Critical patent/US5560168A/en
Assigned to ABLECO FINANCE LLC reassignment ABLECO FINANCE LLC SECURITY AGREEMENT Assignors: HOME DECOR HOLDING COMPANY
Assigned to HOME DECOR COMPANY reassignment HOME DECOR COMPANY ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: STANLEY LOGISTICS, INC., THE STANLEY WORKS
Assigned to ABLECO FINANCE LLC reassignment ABLECO FINANCE LLC SECURITY AGREEMENT Assignors: HOME DECOR COMPANY, HOME DECOR HOLDING COMPANY
Assigned to HOME DECOR COMPANY reassignment HOME DECOR COMPANY RELEASE BY SECURED PARTY (SEE DOCUMENT FOR DETAILS). Assignors: ABLECO FINANCE LLC
Assigned to ABLECO FINANCE LLC reassignment ABLECO FINANCE LLC CORRECTIVE ASSIGNMENT TO CORRECT THE ERRONEOUSLY LISTED HOME DECOR HOLDING COMPANY AS A PARTY TO THE SECURITY AGREEMENT PREVIOUSLY RECORDED ON REEL 015732 FRAME 0184. ASSIGNOR(S) HEREBY CONFIRMS THE SECURITY AGREEMENT. Assignors: HOME DECOR COMPANY
Assigned to GENERAL ELECTRIC CAPITAL CORPORATION, AS ADMINISTRATIVE AGENT reassignment GENERAL ELECTRIC CAPITAL CORPORATION, AS ADMINISTRATIVE AGENT SECURITY AGREEMENT Assignors: RENIN CORP. US
Assigned to RENIN CORP. US reassignment RENIN CORP. US CHANGE OF NAME (SEE DOCUMENT FOR DETAILS). Assignors: HOME DECOR COMPANY
Assigned to GUGGENHEIM CORPORATE FUNDING, LLC, AS ADMINISTRATIVE AGENT reassignment GUGGENHEIM CORPORATE FUNDING, LLC, AS ADMINISTRATIVE AGENT SECURITY AGREEMENT Assignors: RENIN CORP. US
Assigned to GOLDMAN SACHS CREDIT PARTNERS L.P. reassignment GOLDMAN SACHS CREDIT PARTNERS L.P. PATENT SECURITY AGREEMENT Assignors: RENIN CORP. U.S.
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    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B7/00—Special arrangements or measures in connection with doors or windows
    • E06B7/28—Other arrangements on doors or windows, e.g. door-plates, windows adapted to carry plants, hooks for window cleaners
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/54—Fixing of glass panes or like plates
    • E06B3/58—Fixing of glass panes or like plates by means of borders, cleats, or the like
    • E06B3/5892—Fixing of window panes in openings in door leaves
    • E—FIXED CONSTRUCTIONS
    • E06—DOORS, WINDOWS, SHUTTERS, OR ROLLER BLINDS IN GENERAL; LADDERS
    • E06B—FIXED OR MOVABLE CLOSURES FOR OPENINGS IN BUILDINGS, VEHICLES, FENCES OR LIKE ENCLOSURES IN GENERAL, e.g. DOORS, WINDOWS, BLINDS, GATES
    • E06B3/00—Window sashes, door leaves, or like elements for closing wall or like openings; Layout of fixed or moving closures, e.g. windows in wall or like openings; Features of rigidly-mounted outer frames relating to the mounting of wing frames
    • E06B3/70—Door leaves
    • E06B3/72—Door leaves consisting of frame and panels, e.g. of raised panel type
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24149—Honeycomb-like

Definitions

  • the present invention relates to mirrored doors and more particularly, to a hollow core door having a mirror in one face thereof.
  • Mirrored doors are fairly widely employed in interior construction within homes and in some commercial installations.
  • Some mirrored doors for closets comprise mirror panels which are mounted in a peripheral frame to slide back and forth in suitable track.
  • framed mirrors are secured to the surface of wood doors by various types of fasteners.
  • swinging doors which include a mirrored face and a wood face which is panelled or otherwise fabricated to provide desired surface ornamentation in one side of the door opening when closed.
  • hollow core doors with frames to receive mirrors or a framed mirror
  • specially manufactured hollow core doors would generally entail greater costs than conventional hollow core doors since they would be special products.
  • utilizing specially fabricated doors for the mounting of mirrors would minimize the diversity of mirror configurations and sizes which might otherwise be available since many different types of hollow core doors are fabricated for various door openings.
  • Another object is to provide such a hollow core door in which the mirror is securely supported within the body of the door.
  • a further object is to provide a novel and facile method for making such a mirrored hollow core door.
  • the assembly includes a hollow core door having a perimeter frame with stiles and top and bottom rails, and a pair of skins secured to the perimeter frame and providing opposite faces of the door.
  • One of the skins has an aperture therein with its side margins spaced inwardly of the perimeter frame.
  • Elongated inner frame elements extend between the skins and are in the spacing disposed between the margins of the aperture and the stiles, and are secured to at least one of the skins.
  • a mirror cooperatively configured with respect to the aperture has dimensions smaller than those of the aperture, and a molding extends about the periphery of the mirror and retains the mirror therein.
  • the molding has a peripheral portion overlying the one skin about the side margins of the aperture and a body portion extending inwardly of the one skin, and the molding is secured against the one skin.
  • spacer means disposed between the mirror and the other of the skins, and the spacer means is secured to the inner surface of the other skin.
  • the inner frame elements are adhesively bonded to at least one of the skins, and the inner frame elements include stiffening members extending longitudinally thereof.
  • the means securing the molding against the one skin includes adhesive, and there is included adhesive between the molding and the mirror securing them in assembly.
  • the molding may have resiliently deflectable clips on the body thereof which extend outwardly of its periphery behind the skin and bear upon its inner surface.
  • the peripheral portion of the molding has a shoulder on its inner surface which abuts the skin, and a channel intermediate its width is desirably provided into which adhesive may flow.
  • molding may also be included means securing the molding to the inner frame elements such as elongated fasteners extending through the molding and into the inner frame elements.
  • the molding may have a channel extending about the inner periphery of its body portion in which the peripheral portion of the mirror is seated.
  • a retrofit kit for mounting a mirror in an aperture cut in one skin of a hollow core door includes a pair of elongated inner frame elements dimensioned to seat snugly between the skins of the door and against the stiles thereof, these elements are of a width to space them adjacent but inwardly from the margins of the aperture.
  • a mirror is secured in a molding extending about its periphery and the molding has a peripheral portion configured to overlie the one skin about the side margins of the aperture and a body portion dimensioned to extend inwardly of the door.
  • Means is provided for securing the molding against the skin of the door, and there is included a spacer adapted to be mounted on the inner surface of the other skin of the door to provide a support for the rear surface of the mirror.
  • the door is provided with an aperture cut in one of its skins, and the elongated inner frame elements secured between the skins adjacent the margins of the aperture.
  • a spacer member is mounted on the other of the skins within the margins of the aperture.
  • the step of securing the molding in the aperture includes providing an adhesive between an inner shoulder the peripheral portion and the one skin, and it may additionally include driving elongated fasteners through the molding and into the elongated frame elements.
  • FIG. 1 is a front elevational view of the paneled face of a hollow core door embodying the present invention
  • FIG. 2 is a rear elevational view of the door of FIG. 1 prior to insertion of the mirror assembly and with the rear flush face broken away to show the reinforcing frame elements in place;
  • FIG. 3 is a perspective view of a reinforcing frame element with the stiffening element shown prior to insertion thereinto;
  • FIG. 4 is a perspective view of the flush face of the door with a phantom line showing the cutout to be made therein;
  • FIG. 5 is a partially exploded view of a door embodying the present invention.
  • FIG. 6 is a rear elevational view of the assembled mirrored door drawn to a reduced scale
  • FIG. 7 is a fragmentary sectional view of the door along the line 7--7 of FIG. 6 and drawn to an enlarged scale;
  • FIG. 8 is a further enlarged portion of sectional view of FIG. 7;
  • FIG. 9 is a fragmentary perspective view of the reinforcing strip drawn to an enlarged scale
  • FIG. 10 is an end elevational view of an alternate molding providing a channel for seating the mirror
  • FIG. 11 is a fragmentary perspective view of an alternate stiffening member
  • FIG. 12 is a fragmentary perspective view of the molding and mirror assembly being inserted into the aperture in the skin showing a deflectable clip deflecting
  • FIG. 13 is a similar view with the molding seated against the skin and the clip bearing upon the inner surface thereof.
  • FIGS. 1 and 2 is illustrated a hollow core door having a decorative face provided by a first skin generally designated by the numeral 10 and formed with a multiplicity of recessed panels 12 and planar portions 14. The opposite face is provided by a flush surface skin generally designated by the numeral 16 and which has been provided with an aperture 18. The cutout is indicated by the phantom line 18 in FIG. 4.
  • the door has a perimeter frame generally designated by the numeral 20 and provided by relatively narrow stiles 22 and top and bottom rails 24, 26 respectively. Not shown is a block provided along one of the stiles 22 to seat the handle and latch assembly.
  • elongated inner frame elements 28 are disposed adjacent the stiles 22 and secured to the skins and stiles by adhesive (not shown). As seen in FIGS. 3, 8 and 9, they in turn are stiffened by the metallic stiffeners 30 which have barbed tails 32 seated in the longitudinally extending slots or channels 34 therein.
  • a mirror assembly Seated in the aperture 18 is a mirror assembly comprised of the mirror 36 and the molding generally designated by the numeral 38 which extends about its periphery.
  • An elongated spacer 40 is disposed on the inner surface of the skin 10 to provide support for the mirror 36 and to cushion it in the event of impact upon the door.
  • the molding 38 has a peripheral portion 42 which provides a shoulder 43 which overlies the margins of the skin 16 about the aperture 18.
  • the body portion 44 has a recessed portion at its inner end providing a shoulder 46 against which is seated the peripheral portion of the mirror 36.
  • An adhesive compound 48 secures the mirror 36 to the molding 38.
  • peripheral portion 42 of the molding 38 in turn is secured to the skin 16 by the adhesive 50.
  • adhesive 50 to secure the bonding while the adhesive 50 cures and to increase the security of the assembly, elongated finishing nails 52 MAY BE driven diagonally through the molding 38 and into the inner frame elements 28.
  • FIG. 10 there is illustrated a preferred embodiment of the molding 38a which has a channel 54 in the inner periphery of the body portion 56 and a channel or groove 58 intermediate the width of the shoulder 43a into which excess adhesive may flow.
  • FIG. 11 there is illustrated an alternate stiffener 30a which is readily formed from steel strip with a deflectable tab 60 on its leg 62 which will firmly lock in the channel or slot 34 of the inner frame elements 28.
  • FIGS. 12 and 13 show a preferred construction for the molding/mirror assembly which includes deflectable spring clips generally designated by the numeral 64 spaced about the periphery of the molding 38a.
  • the clip 64 has a base portion 66 with a leg 68 which is seated in the body portion 56. It also has a deflectable arm portion 70 with an inturned flange 72 at its free end. When the molding/mirror assembly is moved inwardly of the aperture 18, the arm portion 70 deflects as seen in FIG. 12. When the assembly is fully seated, the arm portion 70 springs outwardly and bears against the inner surface of the skin 16.
  • the hollow core door utilized in the present invention may be one which has been fully fabricated with similar skins on both sides or a decorative skin (e.g., a paneled skin) on one side and a planar skin on the other side in which the mirror assembly will be mounted.
  • the skin in which the mirror is to be mounted may be cut in the finished door assembly to provide the desired aperture.
  • the hollow core door manufacturer may also insert the inner frame elements before assembling one skin, and the manufacturer could also use a precut skin for the skin in which the mirror is to be mounted since these modifications in procedure would not unduly interfere with the normal manufacturing operation.
  • the method of the present invention involves the placement and securing of the inner frame elements between the skins.
  • the frame elements are coated with adhesive on the two faces to be disposed adjacent the skins, and if an edge will abut the stile, adhesive may also be coated on that edge.
  • the inner frame elements are generally fabricated from wood although metal, plastic and laminates may also be used if sufficiently rigid. Because the illustrated wooden frame elements are relatively thin and the principal purpose of the frame elements is to minimize warpage of the door, they are desirably stiffened by the insertion of rigid stiffeners fabricated from metal or a rigid plastic. The frame elements are premilled to provide a slot in which the tail or leg of the stiffener is inserted, and it is conveniently secured within the milled slot or channel by barbs or deflectable tabs which frictionally engage therewithin. Alternative mounting arrangements may be employed.
  • the next step is to mount the spacer on the inside surface of the other skin by a layer of adhesive.
  • a layer of adhesive may be utilized, it has been found that a single elongated spacer is normally sufficient to provide the desired backing to limit deflection and absorb impacts upon the mirror.
  • the spacer may be fabricated from various materials including corrugated board, synthetic resin foam, honeycomb structures and the like.
  • the material should be resiliently deflectable and desirably has high damping characteristics so that it will absorb both impact forces on the mirror and vibrations which might be induced in the mirror. It is not essential that the spacer abut the rear surface of the mirror in its at rest position, but it should be spaced closely adjacent thereto so to provide the desired cushioning effect.
  • the several elements of the molding are also assembled by use of adhesive to bond the ends thereof and brads or corrugated staples may be added to increase the security of that assembly.
  • the mirror is then seated against the shoulder of the molding and secured in place by a bead of a flexible adhesive compound.
  • the molding has a channel in its inner surface to seat the mirror, and it may also use adhesive.
  • the adhesive compound has cured sufficiently to provide firm retention of the mirror in the molding
  • the molding is then coated with adhesive adjacent the juncture of the inner shoulder on its peripheral portion with the body portion. When this adhesively coated molding is placed within the aperture, the adhesive comes into contact with the marginal portions of the skin about the aperture and flows outwardly along the shoulder under pressure.
  • excess adhesive will flow into a groove formed in the shoulder.
  • adhesive and spring clips may be provided to enhance the engagement. Although the adhesive (and spring clips) will normally provide a sufficient bond to the skin to securely mount the mirror assembly thereon, elongated brads may be driven diagonally through the molding and into the inner frame elements 28 to provide additional security to the assembly during the curing of the adhesive.
  • the configuration and dimensions of the mirror assembly may vary widely, and the cutout or aperture in the door skin is cooperatively configured and dimensioned to provide a small clearance about the molding. It is not essential that the inner frame elements be disposed closely adjacent the stiles of the perimeter frame, but they should be of sufficient length and well bonded to the skins so that they will provide stiffness to the door in which the mirror frame assembly is placed to resist warpage of the door.
  • Various types of adhesives may be utilized to effect the bonding of the mirror to the molding, and of the molding to the door skins.
  • a flexible pressure-sensitive, hot melt adhesive has been found highly effective. It is easily applied to the surface of the molding as a bead by a pressurized nozzle, and it provides a high strength bond quickly.
  • a hot melt adhesive is desirably used.
  • This is preferably a high solids, moisture-curing hot melt adhesive which provides very high green strength and a very fast setting speed. It is applied as a bead to the molding before it is seated in the aperture of the skin. After the molding and mirror are seated in the aperture, pressure is applied to the assembly by passing it through a roll nip, or by a platen, or by clamping. This adhesive may also be used to bond the spacer to the skin.
  • the mirrored door of the present invention is one which may be fabricated readily to provide an attractive assembly in which the mirror is firmly supported within a hollow core door.
  • the configuration of the mirror and its frame and their dimensions may be varied for the particular application, and the assembly may be effected by a homeowner through provision of a retrofit kit containing the necessary elements and the appropriate instructions.

Abstract

A hollow core door has a perimeter frame with stiles and top and bottom rails, and a pair of skins secured to the perimeter frame. One skin has an aperture therein with its side margins spaced inwardly of the perimeter frame, and inner frame elements are disposed between the margins of the aperture and the stiles, secured to at least one skin. A mirror with dimensions smaller than those of the aperture is secured in a molding which extends about its periphery of the mirror, and the molding has a peripheral portion overlying the skin about the side margins of the aperture and a body portion which extends inwardly of the door. The molding is secured against the skin.

Description

BACKGROUND OF THE INVENTION
The present invention relates to mirrored doors and more particularly, to a hollow core door having a mirror in one face thereof.
Mirrored doors are fairly widely employed in interior construction within homes and in some commercial installations. Some mirrored doors for closets comprise mirror panels which are mounted in a peripheral frame to slide back and forth in suitable track. In some instances, framed mirrors are secured to the surface of wood doors by various types of fasteners. Recently, there have been produced swinging doors which include a mirrored face and a wood face which is panelled or otherwise fabricated to provide desired surface ornamentation in one side of the door opening when closed.
Although it is possible to specially fabricate hollow core doors with frames to receive mirrors or a framed mirror, such specially manufactured hollow core doors would generally entail greater costs than conventional hollow core doors since they would be special products. Moreover, utilizing specially fabricated doors for the mounting of mirrors would minimize the diversity of mirror configurations and sizes which might otherwise be available since many different types of hollow core doors are fabricated for various door openings.
Accordingly, it is an object of the present invention to provide a novel hollow core door with a mirror in one face thereof.
It is also an object to provide such a door which may utilize a standard hollow core door construction modified to mount a framed mirror within an aperture formed in one face thereof.
Another object is to provide such a hollow core door in which the mirror is securely supported within the body of the door.
A further object is to provide a novel and facile method for making such a mirrored hollow core door.
SUMMARY OF THE INVENTION
It has now been found that the foregoing and related objects may be readily attained in a hollow core door with a mirror in one face thereof. The assembly includes a hollow core door having a perimeter frame with stiles and top and bottom rails, and a pair of skins secured to the perimeter frame and providing opposite faces of the door. One of the skins has an aperture therein with its side margins spaced inwardly of the perimeter frame. Elongated inner frame elements extend between the skins and are in the spacing disposed between the margins of the aperture and the stiles, and are secured to at least one of the skins. A mirror cooperatively configured with respect to the aperture has dimensions smaller than those of the aperture, and a molding extends about the periphery of the mirror and retains the mirror therein. The molding has a peripheral portion overlying the one skin about the side margins of the aperture and a body portion extending inwardly of the one skin, and the molding is secured against the one skin.
Preferably, there is included spacer means disposed between the mirror and the other of the skins, and the spacer means is secured to the inner surface of the other skin.
Desirably, the inner frame elements are adhesively bonded to at least one of the skins, and the inner frame elements include stiffening members extending longitudinally thereof.
Preferably, the means securing the molding against the one skin includes adhesive, and there is included adhesive between the molding and the mirror securing them in assembly. The molding may have resiliently deflectable clips on the body thereof which extend outwardly of its periphery behind the skin and bear upon its inner surface. The peripheral portion of the molding has a shoulder on its inner surface which abuts the skin, and a channel intermediate its width is desirably provided into which adhesive may flow.
There may also be included means securing the molding to the inner frame elements such as elongated fasteners extending through the molding and into the inner frame elements.
The molding may have a channel extending about the inner periphery of its body portion in which the peripheral portion of the mirror is seated.
A retrofit kit for mounting a mirror in an aperture cut in one skin of a hollow core door includes a pair of elongated inner frame elements dimensioned to seat snugly between the skins of the door and against the stiles thereof, these elements are of a width to space them adjacent but inwardly from the margins of the aperture. A mirror is secured in a molding extending about its periphery and the molding has a peripheral portion configured to overlie the one skin about the side margins of the aperture and a body portion dimensioned to extend inwardly of the door. Means is provided for securing the molding against the skin of the door, and there is included a spacer adapted to be mounted on the inner surface of the other skin of the door to provide a support for the rear surface of the mirror.
To assemble the mirror onto the door, the door is provided with an aperture cut in one of its skins, and the elongated inner frame elements secured between the skins adjacent the margins of the aperture. A spacer member is mounted on the other of the skins within the margins of the aperture. The mirror is secured in the molding, and the molding and mirror are placed in the aperture, and the molding is secured against the skin of a door.
Conveniently, the step of securing the molding in the aperture includes providing an adhesive between an inner shoulder the peripheral portion and the one skin, and it may additionally include driving elongated fasteners through the molding and into the elongated frame elements.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a front elevational view of the paneled face of a hollow core door embodying the present invention;
FIG. 2 is a rear elevational view of the door of FIG. 1 prior to insertion of the mirror assembly and with the rear flush face broken away to show the reinforcing frame elements in place;
FIG. 3 is a perspective view of a reinforcing frame element with the stiffening element shown prior to insertion thereinto;
FIG. 4 is a perspective view of the flush face of the door with a phantom line showing the cutout to be made therein;
FIG. 5 is a partially exploded view of a door embodying the present invention;
FIG. 6 is a rear elevational view of the assembled mirrored door drawn to a reduced scale;
FIG. 7 is a fragmentary sectional view of the door along the line 7--7 of FIG. 6 and drawn to an enlarged scale;
FIG. 8 is a further enlarged portion of sectional view of FIG. 7;
FIG. 9 is a fragmentary perspective view of the reinforcing strip drawn to an enlarged scale;
FIG. 10 is an end elevational view of an alternate molding providing a channel for seating the mirror;
FIG. 11 is a fragmentary perspective view of an alternate stiffening member;
FIG. 12 is a fragmentary perspective view of the molding and mirror assembly being inserted into the aperture in the skin showing a deflectable clip deflecting; and
FIG. 13 is a similar view with the molding seated against the skin and the clip bearing upon the inner surface thereof.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIGS. 1 and 2 is illustrated a hollow core door having a decorative face provided by a first skin generally designated by the numeral 10 and formed with a multiplicity of recessed panels 12 and planar portions 14. The opposite face is provided by a flush surface skin generally designated by the numeral 16 and which has been provided with an aperture 18. The cutout is indicated by the phantom line 18 in FIG. 4. As is conventional construction, the door has a perimeter frame generally designated by the numeral 20 and provided by relatively narrow stiles 22 and top and bottom rails 24, 26 respectively. Not shown is a block provided along one of the stiles 22 to seat the handle and latch assembly.
To increase the strength of the door and facilitate mounting of the mirror assembly, elongated inner frame elements 28 are disposed adjacent the stiles 22 and secured to the skins and stiles by adhesive (not shown). As seen in FIGS. 3, 8 and 9, they in turn are stiffened by the metallic stiffeners 30 which have barbed tails 32 seated in the longitudinally extending slots or channels 34 therein.
Seated in the aperture 18 is a mirror assembly comprised of the mirror 36 and the molding generally designated by the numeral 38 which extends about its periphery. An elongated spacer 40 is disposed on the inner surface of the skin 10 to provide support for the mirror 36 and to cushion it in the event of impact upon the door.
As best seen in FIGS. 7 and 8, the molding 38 has a peripheral portion 42 which provides a shoulder 43 which overlies the margins of the skin 16 about the aperture 18. The body portion 44 has a recessed portion at its inner end providing a shoulder 46 against which is seated the peripheral portion of the mirror 36. An adhesive compound 48 secures the mirror 36 to the molding 38.
The peripheral portion 42 of the molding 38 in turn is secured to the skin 16 by the adhesive 50. To secure the bonding while the adhesive 50 cures and to increase the security of the assembly, elongated finishing nails 52 MAY BE driven diagonally through the molding 38 and into the inner frame elements 28.
In FIG. 10 there is illustrated a preferred embodiment of the molding 38a which has a channel 54 in the inner periphery of the body portion 56 and a channel or groove 58 intermediate the width of the shoulder 43a into which excess adhesive may flow.
In FIG. 11, there is illustrated an alternate stiffener 30a which is readily formed from steel strip with a deflectable tab 60 on its leg 62 which will firmly lock in the channel or slot 34 of the inner frame elements 28.
FIGS. 12 and 13 show a preferred construction for the molding/mirror assembly which includes deflectable spring clips generally designated by the numeral 64 spaced about the periphery of the molding 38a. The clip 64 has a base portion 66 with a leg 68 which is seated in the body portion 56. It also has a deflectable arm portion 70 with an inturned flange 72 at its free end. When the molding/mirror assembly is moved inwardly of the aperture 18, the arm portion 70 deflects as seen in FIG. 12. When the assembly is fully seated, the arm portion 70 springs outwardly and bears against the inner surface of the skin 16.
As will be readily appreciated, the hollow core door utilized in the present invention may be one which has been fully fabricated with similar skins on both sides or a decorative skin (e.g., a paneled skin) on one side and a planar skin on the other side in which the mirror assembly will be mounted. The skin in which the mirror is to be mounted may be cut in the finished door assembly to provide the desired aperture. The hollow core door manufacturer may also insert the inner frame elements before assembling one skin, and the manufacturer could also use a precut skin for the skin in which the mirror is to be mounted since these modifications in procedure would not unduly interfere with the normal manufacturing operation.
Whatever the case, the method of the present invention involves the placement and securing of the inner frame elements between the skins. The frame elements are coated with adhesive on the two faces to be disposed adjacent the skins, and if an edge will abut the stile, adhesive may also be coated on that edge.
The inner frame elements are generally fabricated from wood although metal, plastic and laminates may also be used if sufficiently rigid. Because the illustrated wooden frame elements are relatively thin and the principal purpose of the frame elements is to minimize warpage of the door, they are desirably stiffened by the insertion of rigid stiffeners fabricated from metal or a rigid plastic. The frame elements are premilled to provide a slot in which the tail or leg of the stiffener is inserted, and it is conveniently secured within the milled slot or channel by barbs or deflectable tabs which frictionally engage therewithin. Alternative mounting arrangements may be employed.
The next step is to mount the spacer on the inside surface of the other skin by a layer of adhesive. Although more than one spacer may be utilized, it has been found that a single elongated spacer is normally sufficient to provide the desired backing to limit deflection and absorb impacts upon the mirror.
The spacer may be fabricated from various materials including corrugated board, synthetic resin foam, honeycomb structures and the like. The material should be resiliently deflectable and desirably has high damping characteristics so that it will absorb both impact forces on the mirror and vibrations which might be induced in the mirror. It is not essential that the spacer abut the rear surface of the mirror in its at rest position, but it should be spaced closely adjacent thereto so to provide the desired cushioning effect.
The several elements of the molding are also assembled by use of adhesive to bond the ends thereof and brads or corrugated staples may be added to increase the security of that assembly. The mirror is then seated against the shoulder of the molding and secured in place by a bead of a flexible adhesive compound. In the preferred molding construction, the molding has a channel in its inner surface to seat the mirror, and it may also use adhesive. After the adhesive compound has cured sufficiently to provide firm retention of the mirror in the molding, the molding is then coated with adhesive adjacent the juncture of the inner shoulder on its peripheral portion with the body portion. When this adhesively coated molding is placed within the aperture, the adhesive comes into contact with the marginal portions of the skin about the aperture and flows outwardly along the shoulder under pressure. In the preferred embodiment excess adhesive will flow into a groove formed in the shoulder. In addition, adhesive and spring clips may be provided to enhance the engagement. Although the adhesive (and spring clips) will normally provide a sufficient bond to the skin to securely mount the mirror assembly thereon, elongated brads may be driven diagonally through the molding and into the inner frame elements 28 to provide additional security to the assembly during the curing of the adhesive.
As will be appreciated, the configuration and dimensions of the mirror assembly may vary widely, and the cutout or aperture in the door skin is cooperatively configured and dimensioned to provide a small clearance about the molding. It is not essential that the inner frame elements be disposed closely adjacent the stiles of the perimeter frame, but they should be of sufficient length and well bonded to the skins so that they will provide stiffness to the door in which the mirror frame assembly is placed to resist warpage of the door.
Various types of adhesives may be utilized to effect the bonding of the mirror to the molding, and of the molding to the door skins. For bonding the mirror to the molding, a flexible pressure-sensitive, hot melt adhesive has been found highly effective. It is easily applied to the surface of the molding as a bead by a pressurized nozzle, and it provides a high strength bond quickly.
To bond the mirror molding to the skin, a hot melt adhesive is desirably used. This is preferably a high solids, moisture-curing hot melt adhesive which provides very high green strength and a very fast setting speed. It is applied as a bead to the molding before it is seated in the aperture of the skin. After the molding and mirror are seated in the aperture, pressure is applied to the assembly by passing it through a roll nip, or by a platen, or by clamping. This adhesive may also be used to bond the spacer to the skin.
Thus, it can be seen from the foregoing detailed specification and claims that the mirrored door of the present invention is one which may be fabricated readily to provide an attractive assembly in which the mirror is firmly supported within a hollow core door. The configuration of the mirror and its frame and their dimensions may be varied for the particular application, and the assembly may be effected by a homeowner through provision of a retrofit kit containing the necessary elements and the appropriate instructions.

Claims (15)

Having thus described the invention, what is claimed is:
1. A hollow core door with a mirror in one face thereof comprising:
(a) a hollow core door having a perimeter frame with stiles and top and bottom rails, and a pair of skins secured to said perimeter frame and providing opposite faces of said door, one of said skins having an aperture therein with its side margins spaced inwardly of said perimeter frame and the other of said skins providing a continuous surface;
(b) elongated inner frame elements extending between said skins in the spacing between the margins of said aperture and said stiles, said inner frame elements being adhesively bonded to at least one of said skins;
(c) a mirror cooperatively configured with respect to said aperture and having dimensions smaller than those of said aperture;
(d) a molding extending about the periphery of said mirror and retaining said mirror therein, said molding having a peripheral portion overlying the outer surface of said one skin about the side margins of said aperture and a body portion extending inwardly of said one skin;
(e) means securing said molding against said one skin; and
(f) spacer means disposed between said mirror and said other skin of said pair of skins.
2. The mirrored door in accordance with claim 1 wherein said inner frame elements include stiffening members extending longitudinally thereof.
3. The hollow core door in accordance with claim 1 wherein said spacer means is secured to the inner surface of said other skin.
4. The hollow core door in accordance with claim 1 wherein there is a shoulder on the inner surface of said peripheral portion of said molding which abuts said one skin.
5. The hollow core door in accordance with claim 4 wherein said means securing said molding against said one skin includes adhesive between said shoulder and said one skin.
6. The hollow core door in accordance with claim 5 wherein said shoulder has a channel intermediate its width into which said adhesive may flow.
7. The hollow core door in accordance with claim 1 wherein said means securing said molding against said one skin includes resiliently deflectable clips on said body portion of said molding and extending outwardly of the periphery thereof and bearing upon the inner surface of said one skin.
8. The hollow core door in accordance with claim 1 wherein there is included means securing said molding to said inner frame elements.
9. The hollow core door in accordance with claim 8 wherein said means securing said molding to said inner frame elements is elongated fasteners extending through said molding and into said inner frame elements.
10. The hollow core door in accordance with claim 1 wherein there is included adhesive between said molding and said mirror securing them in assembly.
11. The hollow tore door in accordance with claim 1 wherein said body portion of said molding has and outer peripheral side surfaces, the other side surface overlying said one skin about said aperture and the inner side surface having a channel extending about its inner periphery in which said mirror is seated therein.
12. In a method for making a hollow core door having a mirror in one face thereof comprising:
(a) providing a hollow core door having a pair of skins and a perimeter frame with stiles and top and bottom rails, one of said skins having an aperture therein with its side margins spaced inwardly of said perimeter frame and the other of said skins providing a continuous surface, and elongated inner frame elements secured between said skins and between the margins of said aperture and said stiles;
(b) mounting a spacer member on said other of said skins within the margins of said aperture;
(c) securing a mirror having dimensions smaller than those of said aperture in a peripheral molding, said molding having a peripheral portion providing a shoulder extending about the periphery of its outer side;
(d) placing said molding and mirror in said aperture with said shoulder abutting the outer surface of said one skin about said aperture; and
(e) securing said molding against said one skin of said door.
13. The method of making a hollow core door in accordance with claim 12 in which said step of securing said molding against said one skin includes providing an adhesive between said peripheral shoulder and said one skin.
14. The method of making a hollow core door in accordance with claim 12 wherein said providing step includes providing an adhesive on surfaces of said inner frame elements bonding said elements to at least one of said skins.
15. The method of making a hollow core door in accordance with claim 12 wherein said step of securing said mirror in said molding includes placing an adhesive between the peripheral portion of said mirror and said molding to bond said mirror to said molding.
US08/402,003 1995-03-10 1995-03-10 Swinging door with mirror insert on one face and method of making same Expired - Fee Related US5560168A (en)

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US5918434A (en) * 1997-06-06 1999-07-06 American Building Supply, Inc. Simulated panel door structure and method
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EP0931902A3 (en) * 1998-01-23 1999-11-10 Hörmann KG Brockhagen Flat decorative element for decorating a door panel
WO2000063508A1 (en) * 1999-04-15 2000-10-26 Greif Bros. Corporation Multi-panel hollow door structures and manufacturing methods employing paperboard cores
WO2002008556A2 (en) * 2000-07-25 2002-01-31 Gregory Frumkin Panel door construction and method of making same
US20030066257A1 (en) * 2001-10-04 2003-04-10 Barry Shovlin Method for manufacturing a door and door manufactured therefrom
US20040078303A1 (en) * 2002-07-08 2004-04-22 Patridge Daniel E. Method of providing a product line of doors
US20050263256A1 (en) * 2003-01-13 2005-12-01 Wayne-Dalton Corp. Sectional door panel and method of manufacture
US20070094956A1 (en) * 2005-10-05 2007-05-03 Fimbel Iii Edward Carved solid face door and method of fabrication
US20070125044A1 (en) * 2002-10-31 2007-06-07 Jeld-Wen, Inc. Multi-layered fire door and method for making the same
US20090114123A1 (en) * 2007-11-07 2009-05-07 Jeld-Wen, Inc. Thin-layer lignocellulose composites having increased resistance to moisture and methods of making the same
US20090260296A1 (en) * 2008-04-21 2009-10-22 Edward Fimbel, Iii Carved solid face doors having a raised panel design and methods of fabrication
US20110036492A1 (en) * 2003-09-16 2011-02-17 Kenneth Charles Tyler Automated door assembly system and method
US7919186B2 (en) 2003-02-24 2011-04-05 Jeld-Wen, Inc. Thin-layer lignocellulose composites having increased resistance to moisture
US7943070B1 (en) 2003-05-05 2011-05-17 Jeld-Wen, Inc. Molded thin-layer lignocellulose composites having reduced thickness and methods of making same
US8058193B2 (en) 2008-12-11 2011-11-15 Jeld-Wen, Inc. Thin-layer lignocellulose composites and methods of making the same
US20120223626A1 (en) * 2011-03-04 2012-09-06 Vicky Thomas Fashion Accessory Internal Door Storage Cavity
US8646233B2 (en) 2005-10-05 2014-02-11 Edward Fimbel, Iii Carved solid face door having a window formed therein and methods of fabrication
US20150140921A1 (en) * 2013-11-15 2015-05-21 Yorgan Gonzalez Decorative Air Conduit
US9314983B2 (en) 2010-07-28 2016-04-19 Masonite Corporation Automated door assembly, press, and adhesive therefor
US9346185B2 (en) 2010-07-28 2016-05-24 Masonite Corporation Automated door assembly, press, and adhesive therefor
US9511573B2 (en) 2013-07-25 2016-12-06 Masonite Corporation Automated door assembly, press, and adhesive therefor
EP2626498B1 (en) 2012-02-10 2017-01-18 Haustüren-Ring GmbH Door blank with acetylated wood and door comprising such a door blank
US9579818B2 (en) 2013-03-15 2017-02-28 Masonite Corporation Automated door assembly and methods, press used therewith, and adhesive therefor
US9790734B1 (en) 2013-08-02 2017-10-17 American Containers, Inc. Interior reinforcing structure for a door and method of installing an interior reinforcing structure in a door
US10556413B2 (en) 2015-09-11 2020-02-11 JELD-WEN UK, Ltd. Method for assembly of recessed panel doors
USD883518S1 (en) * 2018-07-18 2020-05-05 Adam Jaworski Revolving door weatherstripping
US11255121B1 (en) * 2010-11-23 2022-02-22 Jerry G. Crittenden Hollow core door with perimeter air flow
US11559917B2 (en) 2020-05-08 2023-01-24 Jeld-Wen, Inc. Drop roller press and method of making recessed panel doors

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US5852910A (en) * 1995-01-11 1998-12-29 Jeld-Wen, Inc. Raised panel door
WO1998031911A1 (en) * 1997-01-21 1998-07-23 Premdor, Inc. Mirrored door and method of making same
US5829218A (en) * 1997-01-21 1998-11-03 Premdor, Inc. Mirrored door and method of making same
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US6170224B1 (en) * 1999-04-15 2001-01-09 Greif Bros. Corporation Multi-panel hollow door structures and manufacturing methods employing paperboard cores
WO2002008556A2 (en) * 2000-07-25 2002-01-31 Gregory Frumkin Panel door construction and method of making same
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US6684590B2 (en) 2000-07-25 2004-02-03 Gregory Frumkin Panel door construction and method of making same
WO2002008556A3 (en) * 2000-07-25 2008-05-29 Gregory Frumkin Panel door construction and method of making same
US20030066257A1 (en) * 2001-10-04 2003-04-10 Barry Shovlin Method for manufacturing a door and door manufactured therefrom
US20050223674A1 (en) * 2001-10-04 2005-10-13 Masonite Corporation Method for manufacturing a door and door manufactured therefrom
US20040078303A1 (en) * 2002-07-08 2004-04-22 Patridge Daniel E. Method of providing a product line of doors
US20070125044A1 (en) * 2002-10-31 2007-06-07 Jeld-Wen, Inc. Multi-layered fire door and method for making the same
US7721500B2 (en) 2002-10-31 2010-05-25 Jeld-Wen, Inc. Multi-layered fire door and method for making the same
US20050263256A1 (en) * 2003-01-13 2005-12-01 Wayne-Dalton Corp. Sectional door panel and method of manufacture
US8679386B2 (en) 2003-02-24 2014-03-25 Jeld-Wen, Inc. Thin-layer lignocellulose composites having increased resistance to moisture and methods of making the same
US7919186B2 (en) 2003-02-24 2011-04-05 Jeld-Wen, Inc. Thin-layer lignocellulose composites having increased resistance to moisture
US7943070B1 (en) 2003-05-05 2011-05-17 Jeld-Wen, Inc. Molded thin-layer lignocellulose composites having reduced thickness and methods of making same
US20110036492A1 (en) * 2003-09-16 2011-02-17 Kenneth Charles Tyler Automated door assembly system and method
US10279574B2 (en) 2003-09-16 2019-05-07 Masonite Corporation Automated door assembly system and method
US9555609B2 (en) 2003-09-16 2017-01-31 Masonite Corporation Automated door assembly system and method
US8123895B2 (en) * 2003-09-16 2012-02-28 Masonite Corporation Automated door assembly system and method
US8991462B2 (en) 2003-09-16 2015-03-31 Masonite Corporation Automated door assembly system and method
US8561368B2 (en) 2005-10-05 2013-10-22 Edward Fimbel, Iii Carved solid face door and method of fabrication
US20070094956A1 (en) * 2005-10-05 2007-05-03 Fimbel Iii Edward Carved solid face door and method of fabrication
US8646233B2 (en) 2005-10-05 2014-02-11 Edward Fimbel, Iii Carved solid face door having a window formed therein and methods of fabrication
US20090114123A1 (en) * 2007-11-07 2009-05-07 Jeld-Wen, Inc. Thin-layer lignocellulose composites having increased resistance to moisture and methods of making the same
US8468773B2 (en) 2008-04-21 2013-06-25 Edward Fimbel, Iii Carved solid face doors having a raised panel design and methods of fabrication
US20090260308A1 (en) * 2008-04-21 2009-10-22 Edward Fimbel, Iii Carved solid face doors having inlaid overlays and methods of fabrication
US8225579B2 (en) * 2008-04-21 2012-07-24 Edward Fimbel, Iii Carved solid face doors having inlaid overlays and methods of fabrication
US20090260296A1 (en) * 2008-04-21 2009-10-22 Edward Fimbel, Iii Carved solid face doors having a raised panel design and methods of fabrication
US8058193B2 (en) 2008-12-11 2011-11-15 Jeld-Wen, Inc. Thin-layer lignocellulose composites and methods of making the same
US10315334B2 (en) 2010-07-28 2019-06-11 Masonite Corporation Automated door assembly, press, and adhesive therefor
US10232599B2 (en) 2010-07-28 2019-03-19 Masonite Corporation Automated door assembly and methods, press used therewith, and adhesive therefor
US9346185B2 (en) 2010-07-28 2016-05-24 Masonite Corporation Automated door assembly, press, and adhesive therefor
US10144147B2 (en) 2010-07-28 2018-12-04 Masonite Corporation Automated door assembly, press, and adhesive therefor
US9314983B2 (en) 2010-07-28 2016-04-19 Masonite Corporation Automated door assembly, press, and adhesive therefor
US11255121B1 (en) * 2010-11-23 2022-02-22 Jerry G. Crittenden Hollow core door with perimeter air flow
US20120223626A1 (en) * 2011-03-04 2012-09-06 Vicky Thomas Fashion Accessory Internal Door Storage Cavity
EP2626498B1 (en) 2012-02-10 2017-01-18 Haustüren-Ring GmbH Door blank with acetylated wood and door comprising such a door blank
US9579818B2 (en) 2013-03-15 2017-02-28 Masonite Corporation Automated door assembly and methods, press used therewith, and adhesive therefor
US10427393B2 (en) 2013-07-25 2019-10-01 Masonite Corporation Automated door assembly, press, and adhesive therefor
US9511573B2 (en) 2013-07-25 2016-12-06 Masonite Corporation Automated door assembly, press, and adhesive therefor
US9790734B1 (en) 2013-08-02 2017-10-17 American Containers, Inc. Interior reinforcing structure for a door and method of installing an interior reinforcing structure in a door
US9513025B2 (en) * 2013-11-15 2016-12-06 Yorgan Gonzalez Decorative air conduit
US20150140921A1 (en) * 2013-11-15 2015-05-21 Yorgan Gonzalez Decorative Air Conduit
US10556413B2 (en) 2015-09-11 2020-02-11 JELD-WEN UK, Ltd. Method for assembly of recessed panel doors
US11376834B2 (en) 2015-09-11 2022-07-05 JELD-WEN UK, Ltd. System for assembly of recessed panel doors
USD883518S1 (en) * 2018-07-18 2020-05-05 Adam Jaworski Revolving door weatherstripping
US11559917B2 (en) 2020-05-08 2023-01-24 Jeld-Wen, Inc. Drop roller press and method of making recessed panel doors

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